12 Volt SOLAR POWER

Do It Yourself

Michel Daniek
2nd Ed. Revised & Updated PDF Edition
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Do It Yourself

SOLAR POWER
Michel Daniek

12 Volt

2nd Edition Revised & Updated

Permanent Publications
A Simple Living Series Book

Published by: Permanent Publications Hyden House Limited The Sustainability Centre East Meon, Hampshire GU32 1HR, UK Tel: 01730 823 311 Fax: 01730 823 322 Overseas: (international code + 44 - 1730) Email: info@permaculture.co.uk Web: www.permaculture.co.uk First published 2007, reprinted 2009, 2010. Second edition 2011 2007 Michel Daniek The right of Michel Daniek to be identied as author of this work has been asserted by him in accordance with the Copyright, Designs and Patents Act 1988 Designed and typeset by John Adams and Tim Harland Printed in the UK by CPI Antony Rowe Ltd., Chippenham, Wiltshire Printed on paper from mixed sources certied by the Forest Stewardship Council The Forest Stewardship Council (FSC) is a non-prot international organisation established to promote the responsible management of the worlds forests. Products carrying the FSC label are independently certied to assure consumers that they come from forests that are managed to meet the social, economic and ecological needs of present and future generations. British Library Cataloguing-in-Publication Data A catalogue record for this book is available from the British Library ISBN 978 1 85623 073 5 (pdf edition) All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, rebound or transmitted in any form or by any means, electronic, mechanical, photocopying, recording or otherwise, without the prior permission of Hyden House Limited. Disclaimer Everything in this book has been carefully tested by the author, but neither the author or the publisher shall have liability for any damage or loss (including, without limitation, financial loss, loss of profits, loss of business or any indirect or consequential loss), however it arises, resulting from the use of, or inability to use, the information in this book.

page 11 Solar panels page 15

Electrosmog page 73

Adjustment pages 17 & 95

Welding page 97

Regulators page 33

Batteries page 19

Circular Saws page 93

Cables page 54

Cordless Drills page 88

Relays page 112 Fuses page 55

Solar Grinders page 90

Plugs page 56

Switches page 58

Lamps page 80

Soldering Irons page 109

Food Mixers page 110 Sewing Machines page 111

Slide Projectors page 111

And much, much more...

Contents
Foreword About This Book Introduction Solar Panels Batteries Regulators Watt & Volt Multimeters Cables Fuses Plugs & Polarity Switches Connection Plans Inverters Electrosmog Lamps Music Systems Cordless Tools Solar Grinders Solar Circular Saw Sun-following Systems Solar Welding Battery Tester Special Voltmeter Tips & Tricks Bench Power Supply Home-made Regulators Tables Further Reading 7 9 11 15 19 33 39 47 54 55 56 58 59 69 73 80 84 88 90 93 95 97 100 101 102 119 120 122 123

The Author
Michel Daniek, was born 1964 in Giessen, Germany. He grew up the only son of a plumber and from an early age enjoyed playing in his fathers workshop. Whilst still a teenager he became an industrial mechanic in the motor industry but he soon started wondering if there could be alternative ways of living. He then worked as a bicycle mechanic for handicapped people for many years. But on reaching 30 he found himself totally dissatisfied with the German way of life, bought himself a truck and left in search of other ways to live. During his travels he experimented with a small solar system in his truck and ever since has used solar energy in his day to day life. In 1997 he finally settled in a new home in an alternative village in the sunny south of Spain. He is now married and father of two little daughters and works in many different ecologic and sustainable projects all around Orgiva.

Foreword
by Ben Law
This excellent practical book contains all you need to know to set up a 12 volt, off grid solar system. It contains a wealth of information from constructing 12 volt circular saws to electric guitars. There is even a solution for making a 12 volt washing machine, the holy grail amongst many of us living off the National Grid. Michel Daniek cleverly combines his mechanical training with solar energy to offer many DIY solutions for anyone living or aspiring to live with an autonomous energy supply. I have been living with 12 volt electricity for 16 years, and I have had to learn, change, upgrade and experiment to reach the system I now have at my Woodland House, running on 12 volt solar and wind power with a large battery storage capacity. I made many mistakes along the way, like suffering voltage loss from insufficient sized cables in my first caravan. I struggled to find the necessary knowledge and experience to help me unravel what at the time felt like complex physics. Yet, here in one book are all the answers I needed. Volts, amps, watts and ohms are explained with logical clarity and batteries dont wear out because Michel has solutions to repair them! This is what is so empowering about this book, it allows and encourages you to create simple 12 volt tools from everyday items such as windscreen wiper motors and motorbike starter motors. I am particularly impressed with the bicycle wheel sun following system to gain the maximum potential from your solar panels. And if you have problems with your panels, Michel has answers for how to repair them. For anyone who is living in a truck, bender, caravan, yurt or other low impact dwelling, or if you are inquisitive about options beyond the national grid and alternative energy supplies, DIY 12 Volt Solar Power is full of practical solutions and is sure to become a well thumbed classic for many off griders around the globe. Ben Law Author, woodlander and off grid ecobuilder October 2007

Abbreviations & Symbols

AC DC V W kW kWh A Ah mA mAh Hz kHZ MHz GHz kg kg/l EMF ESAF LED UV Alternating current Direct current Volt Watt Kilowatt Kilowatt hours Ampere Amp hours Milliamp Milliamp hours Ohm Kilo Ohms Mega Ohms Hertz Kilo Hertz Mega Hertz Giga Hertz Kilogram Kilograms per litre Diameter Electromagnetic field Electrostatic alternating field Light emitting diode Ultra violet

About This Book

When I started to work with solar energy, I thought I had found a solution for at least one part of our global problems. Very enthusiastic, I started to give solar workshops all over Germany. I found it quite easy to convince and inspire people but after a year I was sick of telling the same thing over and over again, so I decided to write this book. It was about this time that I moved from cold Germany to this crazy town here in the south of Spain which with its abundant sunshine, has proved a perfect playground for my solar experiments. When I first arrived this area still needed a lot of development many people were still living with candles. It was a pleasure for me to bring the luxury of electric light and music into their lives. However energy use consciousness was sadly lacking. Things developed really quickly and the level of consumer demand soon outpaced the capacity of my small solar systems. Many people changed to using electricity from the National Grid. My idealism with solar energy was badly punished but it opened my eyes to the fundamental problem behind the destruction of our planet: consciousness. I started to write a book about it but the theme is so huge... However I still think that small scale solar energy is an important field of learning to increase awareness of ones own energy use. Its just one little step, but it is a step in the right direction. So... let the sunshine in!!! Thanks to all of you! Thanks for all the great help, enthusiasm, idealism and all the love that the world needs so badly in these times of change. This book was originally written in German in the sunny winter of 1997-98 in El Morreon, Spain. It was translated into English by Cathy Green, Rod Wilson and Abi Hill nearly at the same time. The drawings are by Carma Sola, Demian Oyarce, Michel Daniek and Marion Miller. Proof reading was done by Achim, Felix, Elke, Frederik, Christian, Gnther and Patricia.

In 1999 it was translated into Spanish by Concha Buenaventura and Natalia Rodriguez. A new typed Spanish version will soon be available with great help from Nadin, Timbe-Drums, Armin, Irene, Natalia Rodriguez and Concha Buenaventura. In the summer of 2005, I rewrote and typed out the English version, adding some new material, including many experiences from the previous seven years of living and working with solar electricity in southern Spain. Special thanks for Jeem, Daniel Wahl and Patrick Whitefield for their good help with that. The German version, Einflle statt Abflle Solarstrom in 12V Anlagen, published in 1998, ISBN 3 924038 58 9. You can buy it direct from: Einflle statt Abflle, Christian Kuhtz, Hagebutten str.23, D-24113 Kiel, Germany. Or send a fax order to: +49 431 320 0686. In 2011 a brand new Spanish version was published by Eco-Habitar, Energa Solar en Sistemas de 12 Voltios, ISBN 978 84 614 9792 8. This is available from: Eco-Habitar, Plano Blas 11-13, E-44479 Olba, Teruel, Spain. Tel: +34 978 781 466 Email: gestion@ecohabitar.org For any further questions please write to me at: Michel Daniek, Apartado 254, E-18400 Orgiva, Espaa. Or email: solarmichel@hotmail.com Michel, August 2011

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Introduction
We all know about the problems of CO and radioactivity. Solar electricity is an important step away from the fossil fuel crisis and the potential catastrophe of nuclear energy. Solar is the energy of the future! The number one energy source will always be the sun! However although all the techniques and materials are available, solar energy is not widely used. The technology of using energy direct from the sun is being suppressed by big business and political interests. These groups spread misinformation (see the chapter, Solar Panels, page 15) and use solar models, inventions, projects and studies for the sole purpose of proving them nonviable. They claim that solar energy is too expensive but we should weigh this cost against the true cost of nuclear contamination and CO output from fossil fuels. At the end of the day, the energy industrys only concern is simply to make as much money as possible. With this as their aim the electricity industries produce more electricity than is actually needed, giving consumers the illusion that there is no limit to the amount of fuel they can consume. There is little consciousness of a problem and people rarely think about how much electricity they are using. There is also the problem of electrosmog the electromagnetic field around electricity pylons and wires. High voltage electricity pylons produce an electromagnetic field with a frequency of 50 Hertz (see the chapter, Electrosmog, page 73) which pollutes large areas of land. People are becoming more aware of this problem and minimising it is now one aspect of environmental house building. However studies on damage to living organisms caused by electrosmog are either refused funding or the results are not published.
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The electricity industries do not produce many power saving appliances or teach people to use energy more efficiently. Instead they put products on the market such as TVs with standby buttons and appliances that use power even when theyre switched off. These appliances are continually adding to your fuel bill, CO emissions and creating electromagnetic fields (electrosmog) even when they are not being used. We can stand up to these commercial and political manipulations by using alternative, decentralised energies to show that it is possible to live free from the grip of large energy concerns. We can lead by example! Alternative energy includes fast growing biomass fuels such as rape, hemp and coppiced willow; heaters using insulated storage tanks; solar cars; wind and water energy. Last but not least is photo voltaic energy for producing solar electricity. This must become affordable for everyone and part of our everyday lives. It is important that growth is encouraged the more consumers spend money on solar panels, the more producers will be encouraged to market them, drastically reducing the cost. But within this process there must also be a change in patterns of energy consumption because todays wasteful attitude cannot be the basis of a solar future. For many people, solar energy is already a part of their lives. People with many different motivations are creating new power systems and houses with autonomous energy supplies. There are solar associations spreading information and setting up groups to create solar systems. However whereas a solar water heating system will pay back the initial financial outlay within only a few years, a solar electricity system connected to the National Grid is only financially viable if its on a large scale. Therefore most solar power systems are now in alternative communities where they help to fulfil the desire for an autonomous and ecological life. Low voltage solar power systems can allow us to maintain our standard of living without the electrosmog of the National Grid. Solar power systems with battery storage are being put together by people looking for new ways of living and a way out of this apparent dead end as we become less and less able to ignore the worldwide ecological crisis all around us. More and more people want to act instead of just sitting back and watching the earth being destroyed. Many people would like to have a future!
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We are working on small solutions to our ecological and social problems and creating new ways of living and working. But the way is full of compromises and will therefore be criticized by more radical environmentalists and also by politicians who do not see solar energy as a viable large scale solution. But we shouldnt be surprised that the problems and structures of generations arent overcome within a few days. These problems are within us all and not simply somewhere out there in society. So long as we only try to change individual parts without looking at the whole and all its human causes, our search will be in vain. Small, independent solar systems serve as examples to teach awareness of energy consumption. In terms of the worlds ecological problems these systems are just a drop in the ocean and often bring with them their own ecological problems, for instance energy storage in batteries. But they are important first steps and vital areas for learning. This book aims to provide you with a basic knowledge of solar power systems along with many tips and ideas. I will show you how to build small and medium sized solar power systems made from easily obtainable materials. There is a basic electricity lesson about volts, amperes and watts, and instructions for using a digital multimeter. I would like to show you some simple uses for solar electricity. You will be amazed by the possibilities of solar power!
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Please can I use your electricity for my hammer?

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Solar Panels
These are the heart of every solar power system. They are made from pure silicon crystals. Silicon is the second most common element found in the Earth. Through a special procedure these crystals acquire the property of transporting electrons when light is shone on them. This procedure is very complicated and you could fill a whole book just on this subject. There are different types of solar cells: polycrystalline, monocrystalline, triple cells and amorphous silicon cells. Amorphous silicon cells are dark browny red, easy and cheap to make, and are also used in solar calculators and watches. The big ones have more or less twice the size of the blue Mono- or Poly-crystallines and around 40 long and brown stripes. There have been a lot of experiments with the amorphous silicon cells, like putting them on exible foils or tiles or on glass facades. However they have one disadvantage they all lose power after 8 or 10 years. Triple cells are made from three layers of amorphous silicon, each layer absorbing a different light frequency. This means that they are better than other types of cells at producing power when its cloudy, or when they are partly in shadow. In addition they are cheap. They were an interesting development but you rarely find them. This is because they are also made from amorphous silicon and lose power too quickly, so that they might not even last the promised ten year guarantee period. Mono and Polycrystalline cells have proved effective over many, many years. Polycrystalline cells have nice shining blue crystal patterns. Monocrystalline cells are plain dark blue and give slightly more power per cm than polycrystalline cells. However because polycrystalline cells require less energy to produce, they take less time to recoup the energy that goes into their production. For
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our purposes, polycrystalline cells are the most useful. There are the wildest rumours and scare stories about solar panels such as claims that they are toxic. This story stems from the fact that early models were made with plastics containing Fluoride. However today they are made with PVC instead which is recyclable and non toxic. There are some toxic satellite solar cells but these are not the sort you will find in the shops. Another rumour is that solar cells are ecologically unviable because they require such a large amount of energy to produce. I have information that, depending on the methods of production, solar cells will recoup the energy used within 3 to 7 years. Poly and mono crystalline cells have now been in use for around 45 years and (apart from those which have been damaged) are still working perfectly. The very early solar panels had some problems with broken back covers, so water or humidity could damage the silicon cells. Plus some old series of AEG solar panels were made with aluminium connectors between the single cells inside the panel which also caused problems after 10 years or so. All modern solar panels use silver connectors and do not have these problems. Every single silicon plate in the panel increases the voltage of the panel by 0.55V . Every solar cell has more or less this same voltage regardless of its size because the size of the solar cell affects the power in amperes but not in volts. Therefore to create enough tension (volts) to charge batteries it is necessary to connect a series of many solar cells together, with the bottom (+) of each cell connected to the top (-) of the next one. In this way all the volts are added together. For example 36 solar cells will produce 19.8V when the sun is shining on them. This is the voltage required in order for the electricity to flow into the battery, and therefore most solar panels sold are comprised of 36 cells. The solar plates are combined to make large modules behind special glass coated in PVC to protect it from the weather. The frame is made from aluminium or stainless steel. On the back are the plus and minus connections for the wires. In many solar panels there are also one or more diodes which ensure that energy continues to flow into all the solar cells even when some are in shadow. If you connect two or more
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solar panels together it is better sometimes to separate them with diodes (see the chapter, Connection Plans, page 59). This is useful if you connect solar panels of different output voltages, like different amount (36 and 40) of cells or anytime when there is more than a 2V difference. The biggest natural enemies of solar panels are wind, children and bicycles, so your panels need to be very well installed and ideally high up and out of reach. PLEASE do not let them lie on the ground or lean against a wall. Fix them securely on a roof so that they are safe in storms. Make sure that they are somewhere where shadows (from trees, pylons, etc.) wont fall on them because the shadow of even a few leaves or bird droppings will cause a considerable loss of power. Its good to clean your solar panels from time to time to ensure the greatest possible energy from them. In summer you may get more energy than you need so its good to fix your panels at the correct angle for the winter sun rather than the summer sun. You can find this angle by putting the corner of a book at right angles (90) to the panel and tilting the panel until the shadow of the book disappears (see picture). For travelling people it is easier to keep the panels flat on the roof, otherwise you have to adjust the position of the panel every time you move. They are also less conspicuous this way and less likely to be stolen. And when the sun is not shining the panel gives out the most in the flat position. However a good compromise generally seems to be 45. In summer the sun makes the panels very hot, and cell temperatures of over 65C may actually reduce the power by up to 75%! So its good to have a gap of at least 3cm beneath the panel and the roof, so that the breeze will be able to take away the heat and keep the panels cool.
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It can be clever to position mirrors either side of the panels to reflect the light in from different angles. This is even more effective when you construct a simple machine which will move the panels automatically with the sun. (see also the chapter, Sun-following Systems, page 95). But for many of us this might prove difficult to build and require more energy to construct than you will gain from it. If you make sure that your solar panel is properly fixed, in a safe place where it will not be damaged, you may have it for the rest of your life! The cost of a 50W panel is normally around 300 but many solar associations buy panels in bulk and so it is cheaper to buy though them. A 50W panel is usually enough unless you have equipment requiring a permanent electricity supply (e.g. a fridge). For lighting, music and occasional use of other small equipment (such as a sewing machine, mixer or laptop) a 50W panel can be enough. For calculating how many panels youll need see the chapter, Watt and Volt, page 39. Lately panels with only 50W are running out of fashion, the cheapest panels in relation to Watts and price are now 80W to 120W panels. China has now dropped the price down to 1.30/Watt which is less than the half of what you pay in Europe. The price could go even lower as the costs to make solar panels are around 45p/W . Be very careful, specially when you buy second hand, that you buy a panel with about 20V (+/- 3V) output to charge your 12V batteries. There are many panels now with much higher outputs, 40V or 78V which are used either in 24V systems or in big solar elds connected to the National Grid. Generally these panels can be used to charge a 12V battery, but they will charge only with half or a fourth of the possible power they can output. Some of those can be transformed into a 12V panels, see the chapter: Repairing Solar Panels on Page 107.
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